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Aircraft are designed and built to provide many years of services. For the aircraft to remain airworthy
and safe to operate, they should be operated in accordance with the recommendations of
manufacturer and cared for with inspection and maintenance practices.
Proper maintenance of an aircrafts structural integrity can be a demanding task. Aircraft are subjected
to a variety of influences, which can affect their ability to withstand the rigors of flight. Failure or
potential failure of airframe components is not always easy to identify. However, once a potential
failure is identified, it must be evaluated is extent of discrepancy, determine its causes, determine the
proper corrective action or repair and repaired.
Inspection
Airframe inspection may range from a casual walk around to detail inspection involving complete
disassembly and the use of complex inspection aids. Traditionally, the inspections are classified as a
destructive or non-destructive. Maintenance is concerned with non-destructive testing, since
destructive testing eliminates the serviceability of part or material being tested.
Non-Destructive Testing
Non-destructive testing, also called NDT, non-destructive evaluation, NDE, and non-destructive
inspection, NDI is a test that does not destroy the test object. While destructive testing usually
provides a more reliable assessment of the state of the test object, destruction of the test object
usually makes this type of test more costly. Destructive testing is also inappropriate in many
circumstances. There is a tradeoff between the cost of the test and its reliability favors a strategy in
which most test objects are inspected non-destructively. Destructive testing is performed on a
sampling of test objects that is drawn randomly for characterizing the testing reliability of the nondestructive test.
Methods and techniques
NDT is divided into various methods of non-destructive testing, each based on a particular scientific
principle. These methods may be further subdivided into various techniques as listed in Table 1.
Table 1: Methods and Techniques of Non-destructive Testing
Method
Technique
Acoustic-impact technique
Interferometry
Thermographic inspection
Laser testing
Profilometry
Holography / Stereography
Bubble testing
Absolute pressure leak testing (pressure change)
Halogen diode leak testing
Mass spectrometer leak testing
Post-emulsifiable testing
Solvent-removable testing
Water-washable testing
Ellipsometry
Pipeline video inspection
The various methods and techniques, due to their particular natures, may lend themselves especially
well to certain applications and be of little or no value at all in other applications. Therefore choosing
the right method and technique is an important part of the performance of NDT.
Regardless of application or method, all nondestructive testing shares the same basic elements:
a. Source source provides a medium for testing.
b. Modification the probing material must be modified due to variation in the source.
c.
Detection a detector that will determine the changes on the probing medium.
paper. Any colored stains indicate the positions and types of defects in the surface under
inspection. The penetrants are usually red, purple or sometimes orange, to give a good contrast
against the white developer used in the process.
Magnetic-particle inspection
Magnetic particle inspection processes are non-destructive methods for the detection of defects in
ferrous materials. They make use of an externally applied magnetic field or DC current through
the material, and the principle that the magnetic susceptibility of a defect is markedly poorer (the
magnetic resistance is greater) than that of the surrounding material.
The presence of a surface or near surface flaw (void) in the material causes distortion in the
magnetic flux through it, which in turn causes leakage of the magnetic fields at the flaw. This
deformation of the magnetic field is not limited to the immediate locality of the defect but extends
for a considerable distance; even through the surface and into the air if the magnetism is intense
enough. Thus, the size of the distortion is much larger than that of the defect and is made visible
at the surface of the part by means of the tiny particles that are attracted to the leakage fields.
The most common method of magnetic particle inspection uses finely divided iron or magnetic
iron oxide particles, held in suspension in a suitable liquid (often kerosene). This fluid is referred
to as carrier. The particles are often colored and usually coated with fluorescent dyes that are
made visible with a hand-held ultraviolet (UV) light. The suspension is sprayed or painted over the
magnetized specimen during magnetization with a direct current or with an electromagnet, to
localize areas where the magnetic field has protruded from the surface. The magnetic particles
are attracted by the surface field in the area of the defect and hold on to the edges of the defect to
reveal it as a build up of particles.
This inspection can be applied to raw material in a steel mill (billets or slabs), in the early stages
of manufacturing (forgings, castings), or most commonly to machined parts before they are put
into service. It is also very commonly used for inspecting structural parts (e.g. landing gear) that
have been in-service for some time to find fatigue cracks.
Radiographic Testing
Radiographic Testing (RT), or industrial radiography, is a nondestructive testing (NDT) method of
inspecting materials for hidden flaws by using the ability of short wavelength electromagnetic
radiation (high-energy photons) to penetrate various materials.
Either an X-ray machine or a radioactive source (Ir-192, Co-60, or in rare cases Cs-137) can be
used as a source of photons. Neutron radiographic testing (NR) is a variant of radiographic testing
which uses neutrons instead of photons to penetrate materials. This can see very different things
from X-rays, because neutrons can pass with ease through lead and steel but are stopped by
plastics, water, and oils.
Since the amount of radiation emerging from the opposite side of the material can be detected
and measured, variations in this amount (or intensity) of radiation are used to determine thickness
or composition of material. Penetrating radiations are those restricted to that part of the
electromagnetic spectrum of wavelength less than about 10 nanometers.
Ultrasonic Testing
In ultrasonic testing, ultrasonic waves of frequencies ranging from 0.5-15MHz and occasionally up
to 50MHz are used to detect flaws.
Advantages
a. Superior penetrating power, which allows the detection of flaws deep in the part.
b. High sensitivity, permitting the detection of extremely small flaws.
c.
d. Greater accuracy than other nondestructive methods in determining the depth of internal
flaws and the thickness of parts with parallel surfaces.
e. Some capability of estimating the size, orientation, shape, and nature of defects.
f.
Parts those are rough, irregular in shape, very small or thin, or not homogeneous are difficult
to inspect.
d. Couplants are needed to provide effective transfer of ultrasonic wave energy between
transducers and parts being inspected.
Inspection of welds
The beam of radiation must be directed to the middle of the section under examination and must be
normal to the material surface at that point, except in special techniques where known defects are
best revealed by a different alignment of the beam. The length of weld under examination for each
exposure shall be such that the thickness of the material at the diagnostic extremities, measured in
the direction of the incident beam, does not exceed the actual thickness at that point by more than
6%. The specimen to be inspected is placed between the source of radiation and the detecting
device, usually the film in a light tight holder or cassette, and the radiation is allowed to penetrate the
part for the required length of time to be adequately recorded.
The result is a two-dimensional projection of the part onto the film, producing a latent image of varying
densities according to the amount of radiation reaching each area. It is known as a radiograph, as
distinct from a photograph produced by light. Because film is cumulative in its response (the exposure
increasing as it absorbs more radiation), relatively weak radiation can be detected by prolonging the
exposure until the film can record an image that will be visible after development. The radiograph is
examined as a negative, without printing as a positive as in photography. This is because, in printing,
some of the detail is always lost and no useful purpose is served.
Before commencing a radiographic examination, it is always advisable to examine the component
with one's own eyes, to eliminate any possible external defects. If the surface of a weld is too
irregular, it may be desirable to grind it to obtain a smooth finish, but this is likely to be limited to those
cases in which the surface irregularities (which will be visible on the radiograph) may make detecting
internal defects difficult.
After this visual examination, the operator will have a clear idea of the possibilities of access to the
two faces of the weld, which is important, both for the setting up of the equipment and for the choice
of the most appropriate technique.
Defects such as delaminations and planar cracks are difficult to detect using radiography, which is
why penetrants are often used to enhance the contrast in the detection of such defects. Penetrants
used include silver nitrate, zinc iodide, chloroform, and diiodomethane. Choice of the penetrant is
determined by the ease with which it can penetrate the cracks and with which it can be removed.
Diiodomethane has the advantages of high opacity, ease of penetration, and ease of removal
because it evaporates relatively quickly. However, it can cause skin burns.
Safety
Industrial radiography appears to have one of the worst safety profiles of the radiation professions,
possibly because there are many operators using strong gamma sources (> 2 Ci) in remote sites with
little supervision when compared with workers within the nuclear industry or within hospitals. Many of
the lost source accidents commented on by the IAEA involve radiography equipment. Lost source
accidents have the potential to cause a considerable loss of human life, one scenario is that a passer
by finds the radiography source and not knowing what it is, takes it home. The person shortly
afterwards becomes ill and dies because of the radiation dose. The source remains in their home
where it continues to irradiate other members of the household.